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Yamaha TW125-2002

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Comments to date: 1. Page 1 of 1. Average Rating:
sithlord 9:57pm on Wednesday, May 5th, 2010 
The Yamaha TW125 is a great bike for learners its my first bike, I was riding grand after 1 day. Not a lot of power. I love this bike and will not get rid of it until its unrideable it is an expencive bike to run but well worth it. I only had the bike for three months, due the constant cut-outs... I got this bike after a passed my cbt its a great bike have not had any problems with it so far. Really good bike for begginers. Great runner.

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Documents

doc0

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the TW125 2002. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. TW125 SERVICE MANUAL: 5EK1-AE1
TWSUPPLEMENTARY SERVICE MANUAL E2001 by Yamaha Motor Co., Ltd. First Edition, August 2001 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EB001000

NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycle has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

CAUTION:

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to SYMBOLS on the following page. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (Periodic Inspections and Adjustments), where the sub-section title(-s) appear.
(In Chapter 3, Periodic Inspections and Adjustments, the sub-section title appears at the top of each page, instead of the section title.)
3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced (see SYMBOLS). 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially.

EAS00009

SYMBOLS
The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) 6 Chassis 7 Electrical system 8 Troubleshooting

GEN INFO

CHK ADJ

TRBL SHTG

Symbols 9 to 16 indicate the following. 9 Serviceable with engine mounted
Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data
Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points.
Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap base grease Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indicate the following:
23 Apply locking agent (LOCTITER) 24 Replace the part

CONTENTS

SPECIFICATIONS GENERAL SPECIFICATIONS. MAINTENANCE SPECIFICATIONS. ENGINE. CHASSIS. ELECTRICAL. CABLE ROUTING. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION. PERIODIC MAINTENANCE/LUBRICATION INTERVALS. ENGINE. ADJUSTING THE ENGINE IDLING SPEED. ADJUSTING THE THROTTLE CABLE FREE PLAY. ELECTRICAL SYSTEM. CHECKING AND CHARGING THE BATTERY. REPLACING THE HEADLIGHT BULB. ADJUSTING THE HEADLIGHT BEAM. ENGINE CLUTCH 5 6
CARBURETOR CARBURETOR. CHECKING THE CARBURETOR. ASSEMBLING THE CARBURETOR. INSTALLING THE CARBURETOR. MEASURING AND ADJUSTING THE FUEL LEVEL. CHASSIS FRONT WHEEL AHD BRAKE DISC. REAR WHEEL AND REAR BRAKE. REAR WHEEL. REAR BRAKE AND REAR WHEEL SPROCKET. FRONT FORK. HANDLEBAR. STEERING HEAD. LOWER BRACKET.
ELECTRICAL SYSTEM IGNITION SYSTEM. 49 CIRCUIT DIAGRAM. 49 CHECKING THE IGNITION SYSTEM. 50 TWWIRING DIAGRAM

GENERAL SPECIFICATIONS

SPECIFICATIONS
Model Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Carburetor: Type/quantity Manufacturer Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Tire: Type Size 5RS1, 5RS2 2,135 mm ,820 mm 1,120 mm ,820 mm 1,350 mm ,255 mm 2,100 mm MV28/1 TEIKEI Spur gear 74/20 (3.700) Chain drive 51/14 (3.643) Constant mesh 5 speed Left foot operation 36/16 (2.250) 31/21 (1.476) 27/24 (1.125) 25/27 (0.926) 23/29 (0.793) Diamond 25_mm Tube type 130/80-18 66P 130/80-18 M/C 66P 180/80-14 M/C 78P BRIDGESTONE BRIDGESTONE TW203 TW204 TW125
rear Manufacture front rear Type front rear
Model Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Bulb wattage quantity: Headlight Auxiliary light Tail/brake light Turn signal light Meter light High beam indicator light Neutral indicator light Turn signal indicator light 150 mm 150 mm C.D.I. A.C. magneto GT6B-V 6 AH 12 V 60 W/55 W 12 V 4 W V 5 W/21 W 12 V 21 W V 3.4 W V 3.4 W V 3.4 W V 3.4 W 1 TW125
MAINTENANCE SPECIFICATIONS
ENGINE Item Clutch: Friction plate thickness Quantity Clutch plate thickness Quantity Clutch spring free length Quantity Push rod bending limit Carburetor: Type I.D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilot air jet 2 Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Bypass 4 Pilot screw Valve seat size Starter jet 1 Starter jet 2 Fuel level Engine idle speed Intake vacuum TIGHTENING TORQUES ENGINE Part to be tightened g Cam sprocket cover Oil filter cover Crankcase (left and right) Generator cover Clutch cover Clutch boss Drive sprocket Pick up coil Stator coil Thread Part name size Screw Screw Screw Screw Screw Nut Bolt Screw Screw M6 M6 M6 M6 M6 M14 M5 M6 M6 Qty y 3 Tightening torque Nm 10 mSkg 1.0 1.0 1.0 1.0 1.0 5.0 0.4 1.0 1.0 Remarks Standard 2.9 X 3.1 mm 5 pcs. 1.6 mm 4 pcs. 34.9 mm 4 pcs. SSS MV28 5RS#134 1.2 5A50-3/5 B1/60 #90 #120 0.8 #34 0.7 0.7 0.7 0.7 1-1/2 1.6 0.6 0.X 2.0 mm 1,450 X 1,650 r/min 190 X 230 mmHg Limit 2.7 mm SSS 0.05 mm SSS 33.9 mm SSS 0.2 mm

CABLE ROUTING

1 Brake hose 2 Throttle cables 3 Front brake light switch lead 4 Right handlebar switch lead 5 Main switch lead 6 Clutch cable 7 Clutch switch lead 8 Speedometer cable 9 Left handlebar switch lead 10 Front turn signal light lead (left) 11 Meter lead 12 Wire harness 13 Front turn signal light lead (right) 14 Indicator lead
A Clamp the grommet of brake hose with the band. After completion of clamping, cut the surplus part and point it to the backward. B No positioning for the headlight body is specified. C To the headlight
1 Battery positive lead 2 Starter relay 3 Starter motor lead 4 Clamp 5 Ignition coil 6 Throttle cable (pull side) 7 Throttle cable (return side) 8 Throttle cable holder 9 Horn lead 10 Spark plug lead 11 Relay (White) 12 C.D.I. unit 13 Diode 14 Resister lead 15 Turn signal relay
A After clamping the wire harness, point the surplus part to the downward. Clamp the part immediately before the junction to the C.D.I. unit and relay. B Cut it to be 10 mm or less. C Handlebar switch lead (right) and front brake light switch lead should not be twined around.
D Clamp the wire harness, handle switch lead, main switch lead, bar switch lead (right), front resonator hose and starter brake light switch lead, clutch cable. switch lead and main switch F Clamp the ignition coil lead and lead. After clamping, point the the ignition coil grand lead horn surplus part to the downward lead. and then cut it. Do not clamp the G Route the wire harness, handleresonator hose and starter bar switch lead (right) and front cable. brake light switch lead through E Clamp the wire harness, handlethe guide. bar switch lead (right), front H Do not bend the lead sharply just brake light switch lead, clutch after the terminal connection.
I Pass the throttle cables through the engine bracket hole. Point the surplus part to the downward and cut the end. J Pass the carburetor heater lead in front of the seat pillar tube so that it is not caught between the side cover flange and seat pillar tube frame. K Point the rear brake switch lead wire to the rear side of frame.
L Clamp the rear brake switch lead O Clamp the wire harness and connector and turn signal relay diode. Point the surplus part to lead with the band and point the the downward. surplus part to the inner side, then cut it. Secure the connector at the front part of frame. M Push the wire harness in between frame and box. N Place the C.D.I. unit on the mounting port for the left side relay.

1 Resonator hose 2 Fuel hose 3 Rectifier/ regulator lead 4 Thermo switch lead 5 Sidestand switch lead 6 Air filter case 7 Breather hose 8 Battery negative lead 9 C.D.I. magneto leads 10 Over flow hose 11 Air vent hose 12 Clutch cable 13 Clutch cable guide 14 Brake hose 15 Speedometer cable 16 Handlebar switch lead (left) 17 Clamp 18 Flange bolt 19 Brake hose holder
A Clamp between the positioning belts of resonator hose. Do not pinch the resonator hose. B Starter cable, clutch switch lead and main switch lead should not be twined around. C Clamp at the point ahead of the part where resonator hose protector is torn. Do not pinch the resonator hose. D Place the coupler below the resonator hose.
E Clamp the rectifier / regulator lead and resonator hose. Point the surplus part toward the inner side. Clamp within a range where the resonator hose protector is torn. Do not pinch the resonator hose. F Place the air vent hose in the inner side of the main pipe. G Clamp the C.D.I. magneto lead at the frame pipe bend and point the surplus part to the inner
side, then cut it. tween engine and swingarm. H Clamp the sidestand switch M Route the neutral switch lead belead. tween engine and swingarm. I Clamp the air vent hose, over N Route the air vent hose and over flow hose, starter motor lead and flow hose through the engine neutral switch lead. guide. J Hold down the side stand switch O To the fuel cock. lead using the special washer. P Route the horn lead through inK Route the air vent hose and over side the clutch cable. flow hose between engine and Q Insert the starter cable to the swingarm. clamp. L Route the starter motor lead be-
R Clamp the brake hose and V Place the speedometer cable in speedometer cable. Align the the inner side. clamping position with the center W After tightening screws, insert of white paint mark on the brake the hose in the screw section. hose. X Distortion should be within this S Clamp the brake hose and range toward the traveling direcspeedometer cable with a holdtion of vehicle. er. Y Place the brake hose in the outer T Point the speedometer cable side. cap to the backward. U Make sure to push in the boot fully.
1 Handlebar switch lead (right) 2 Front brake light switch lead 3 Brake hose 4 Throttle cable (return side) 5 Throttle cable (pull side) 6 Starter motor lead 7 Battery positive lead 8 Wire harness 9 Clamp (wire harness) 10 Thermo switch lead 11 Sidestand switch lead 12 Negative lead 13 Battery negative lead 14 Grommet 15 Rectifier/ regulator 16 Clamp (rectifier / regulator lead) 17 Handlebar switch lead (left) 18 Clutch switch lead 19 Clutch cable 20 Master cylinder 21 Starter cable 22 Rear turn signal light lead 23 Turn signal light stay

24 C.D.I. magneto leads, neutral

switch lead

A Clamp the handlebar switch lead D Clamp the wire harness and rear and front brake light switch lead turn signal light lead (right). Point with a band. the surplus part to the inner side. B Clamp the throttle cables. E Cover the naked part of rear turn C Clamp the C.D.I. magneto lead signal light lead (right) with the (2 leads), starter motor lead, hose. neutral switch lead, battery neg- F Cover the naked part of rear turn ative lead and pass them signal light lead (left) with the through the frame gusset hole, hose. then point the surplus part to the G Clamp the wire harness and rear inner side. turn signal lead (right).
H Pass the rear turn signal light lead (right) between the rear frame and license bracket, avoiding to be caught. I Pass the rear turn signal light lead (left) between the rear frame and license bracket, avoiding to be caught. J Clamp the rear turn signal light lead (left). After clamping, point the surplus part to the inner side.
K Clamp the thermo switch lead O Clamp the handlebar switch lead coupler. After clamping, point (left) and clutch switch lead. the surplus part to the inner side. P After clamping, cut where it is not L Pass the C.D.I. magneto lead (2 visible either from the top or the leads) through the grommet rear. side. M Place the cover to the corner of rectifier / regulator. N No special order is set for the C.D.I. magneto lead (2 leads), neutral switch lead, starter motor lead and battery negative lead.
INTRODUCTION PERIODIC MAINTENANCE/LUBRICATION INTERVALS

EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.

EAS00037

PERIODIC MAINTENANCE/LUBRICATION INTERVALS
NOTE: S The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. S From 30,000 km, repeat the maintenance intervals starting from 6,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
ODOMETER READING ( 1,000 km) * Fuel line S Check fuel hoses for cracks or damage. S Check condition. S Clean and regap. S Replace. 3 * Valves S Check valve clearance. S Adjust. S Clean. S Replace. S Check operation. S Adjust. S Check operation, fluid level and vehicle for fluid leakage. S Replace brake pads. S Check operation and adjust brake pedal free play. S Replace brake shoes. S Check for cracks or damage. S Replace. S Check runout, spoke tightness and for damage. S Tighten spokes if necessary. S S S S Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 6 24

CHECK OR MAINTENANCE JOB

ANNUAL CHECK

Spark plug p p g

Air filter element

Clutch

Front brake
Whenever worn to the limit

Rear brake

Brake hose

Every 4 years

Wheels

Wheel bearings Swingarm

S Check bearing for looseness or damage. S Check operation and for excessive play. S Lubricate with lithium-soap-based grease. S Check chain slack. S Make sure that the rear wheel is properly aligned. S Clean and lubricate. S Check bearing play and steering for roughness. S Lubricate with lithium-soap-based grease. S Make sure that all nuts, bolts and screws are properly tightened. S Check operation. S Lubricate. S Check operation. S Check operation and for oil leakage. S Check operation and shock absorber for oil leakage.
Every 24,000 km Every 500 km and after washing the motorcycle or riding in the rain

Drive chain

Steering bearings

Every 24,000 km

Chassis fasteners Sidestand
Sidestand switch Front fork Shock absorber assembly
NO. ITEM CHECK OR MAINTENANCE JOB * Rear suspension relay arm and connecting arm pivoting points Carburetor Engine oil Engine oil filter element * * Engine oil strainer Front and rear brake switches Moving parts and cables * Lights, signals and switches S Check operation. S Lubricate with lithium-soap-based grease. S Check starter (choke) operation. S Adjust engine idling speed. S Change. S Check oil level and vehicle for oil leakage. S Clean. S Clean. S Check operation. S Lubricate. S Check operation. S Adjust headlight beam.
ANNUAL CHECK 24 12 18
ODOMETER READING ( 1,000 km) 6
NOTE: D The air filter needs more frequent service if you are riding in unusually wet or dusty areas. D Hydraulic brake service S Regularly check and, if necessary, correct the brake fluid level. S Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. S Replace the brake hoses every four years and if cracked or damaged.
ADJUSTING THE ENGINE IDLING SPEED

ENGINE

EAS00054
ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Install: S engine tachometer (to the spark plug lead) Engine tachometer 90890-03113 3. Measure: S engine idling speed Out of specification ! Adjust. Engine idling speed 1,450 X 1,650 r/min 4. Adjust: S engine idling speed a. Turn the pilot screw 1 in or out until it is lightly seated. b. Turn the pilot screw out the specified number of turns. Pilot screw 1-1/2 turns out c. Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained. Direction a ! Engine idling speed is increased. Direction b ! Engine idling speed is decreased.

5. Adjust: S throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm
ADJUSTING THE THROTTLE CABLE FREE PLAY

EAS00058

ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm 2. Adjust: S throttle cable free play NOTE: When the motorcycle is accelerating, the accelerator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable. c. Loosen the locknut 4 on the accelerator cable 1. d. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained. Direction a Direction b Throttle cable free play is increased. Throttle cable free play is decreased.
e. Tighten the locknuts. NOTE: If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side. Handlebar side a. Slide back the rubber cover 1. b. Loosen the locknut 2. c. Turn the adjusting nut 3 in direction a or b until the specified throttle cable free play is obtained.

Direction a Direction b

Throttle cable free play is increased. Throttle cable free play is decreased.

d. Tighten the locknut.

After adjusting the throttle cable free play, turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.
CHECKING AND CHARGING THE BATTERY

EAS00178

ELECTRICAL SYSTEM
Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. S Charge batteries in a well-ventilated area. S Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). S DO NOT SMOKE when charging or handling batteries. S KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. S Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. First aid in case of bodily contact: External S SKIN Wash with water. S EYES Flush with water for 15 minutes and get immediate medical attention. Internal S Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.

Ambient temperature 20_C

Charging condition of the battery (%)
Charging method using a variable voltage charger Measure the open-circuit voltage prior to charging. Connect a charged and AMP meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery.
NOTE: Voltage should be measured 30 minutes after the machine is stopped.
NOTE: Set the charging voltage at 16 X 17 V. (If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged.)
By turning the charging voltage adjust dial, set the charging voltage at 20 X 24 V. Adjust the voltage so that the current is at the standard charging level. YES Monitor the amperage for 3 X 5 minutes to check if the standard charging current is reached. NO
Set the time according to the charging time suitable for the open-circuit voltage. Refer to Battery condition checking steps.
If the current does not exceed the standard charging current after 5 minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.
Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging.
Connect a charger and AMP meter to the battery and start charging.
Make sure that the current is higher than the standard charging current written on the battery.
Charge the battery until the batterys charging voltage is 15 V. Charge the battery until the batterys charging voltage is 15 V.
NOTE: Set the charging time at 20 hours (maximum).
This type of battery charger cannot charge the MF battery. A variable voltage charger is recommended.
Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.
6. Check: S battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: S battery
8. Connect: S battery leads (to the battery terminals)

First, connect the positive lead 1 , then the negative lead 2. 9. Check: S battery terminals Dirt ! Clean with a wire brush. Loose connection ! Connect properly. 10. Lubricate: S battery terminals Recommended lubricant Dielectric grease 11. Install: S seat
REPLACING THE HEADLIGHT BULB

EAS00182

REPLACING THE HEADLIGHT BULB 1. Remove: S bolts 1 S headlight unit
2. Disconnect: S headlight coupler 1 S headlight bulb cover 2
3. Remove: S headlight bulb holder 1 S headlight bulb 2
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: S headlight bulb New Secure the new headlight bulb with the headlight bulb holder.
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 5. Install: S headlight bulb holder 6. Connect: S headlight bulb holder S headlight coupler 7. Install: S headlight unit
ADJUSTING THE HEADLIGHT BEAM

EAS00184

ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b. Direction a ! Headlight beam is raised. Direction b ! Headlight beam is lowered. 2. Adjust: S headlight beam (horizontally) a. Turn the adjusting knob 2 in direction a or b. Direction a ! Headlight beammoves to the right. Direction b ! Headlight beammoves to the left.

CLUTCH

EAS00274
8 Nm (0.8 mSkg) 70 Nm (7.0 mSkg)

12 Nm (1.2 mSkg)

6 Nm (0.6 mSkg)

Order 11

Job/Part Removing the clutch Clutch springs Pressure plate Friction plates Clutch plates Nut/Lock washer Clutch boss Thrust washer Clutch housing Ball Long clutch push rod Push lever screw/Gasket

Qty 1/1/1

Remarks Remove the parts in the order listed.

Refer to REMOVING/INSTALLING THE CLUTCH section in chapter 4. (Manual No.: 5EK1-AE1)

8 Nm (0.8 mSkg)

70 Nm (7.0 mSkg)

Order 12

Job/Part Push lever axle
Remarks Refer to INSTALLING THE CLUTCH section in chapter 4. (Manual No.: 5EK1-AE1)
Torsion spring Circlip Oil seal Nut/Washer
Refer to INSTALLING THE CLUTCH section in chapter 4. (Manual No.: 5EK1-AE1)
Short clutch push rod/O-ring Push plate
1/For installation, reverse the removal procedure.

CARBURETOR

EAS00480
Job/Part Removing the carburetor Side cover Seat Fuel tank Heater unit lead Starter cable
Remarks Remove the parts in order listed. Refer to SEAT, FUEL TANK AND SIDE COVER section in chapter 3. (Manual No.: 5EK1-AE1) NOTE: S Disconnect the connector from carburetor. S Disconnect the starter cable.
Carburetor joint clamp screw Air filter joint clamp screw Carburetor assembly Throttle cables

Loosen.

For installation, reverse the removal procedure.

EAS00483

Job/Part Disassembly the carburetor Vacuum chamber cover Piston valve spring Jet needle holder Jet needle spring Jet needle Piston valve Carburetor heater Adjusting screw Drain screw Float chamber Gasket
Remarks Disassemble the parts in the order listed.
Refer to ASSEMBLING THE CARBURETOR.
Job/Part Float pin Float Needle valve Needle valve seat Main jet Main jet holder Needle jet Pilot jet Pilot screw Rubber diaphragm spring Rubber diaphragm Starter plunger

Qty 1 1

For assembly, reverse the disassembly procedure.

EAS00485

CHECKING THE CARBURETOR 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air.
3. Check: S float chamber body Dirt ! Clean. 4. Check: S float chamber rubber gasket Cracks/damage/wear ! Replace.
5. Check: S float Damage ! Replace.
6. Check: S needle valve 1 S needle valve seat 2 Damage/obstruction/wear ! Replace the needle valve, needle valve seat and O-ring as a set. 7. Check: S O-ring 3 Damage/wear ! Replace the needle valve, needle valve seat and O-ring as a set.
8. Check: S piston valve 1 Damage/scratches/wear ! Replace. S rubber diaphragm 2 Cracks/tears ! Replace.
9. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder 3 S jet needle spring 4 Cracks/damage ! Replace.
10. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S main jet holder 4 S pilot jet 5 S pilot screw 6 Bends/damage/wear ! Replace. Obstruction ! Clean. Blow out the jets with compressed air. 11. Check: Spiston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness ! Replace the piston valve.

12 Check: S starter plunger 1 S starter plunger spring 2 Bends/cracks/damage ! Replace.
13. Check: S fuel hoses Cracks/damage/wear ! Replace. Obstruction ! Clean. Blow out the hoses with compressed air.

EAS00487

ASSEMBLING THE CARBURETOR
S Befor assembling the carburetor, wash all of the parts in a petroleum-based solvent. S Always use a new gasket.
1. Install: S needle jet S main jet 1 S main jet holder 2 S pilot jet 3
2. Install: S needle valve seat 1
3. Install: S float 1 S needle valve S float pin 2 NOTE: Install the float pin from the side opposite the arrow.
4. Install: S float chamber 1 S pilot screw 2
5. Install: S starter plunger kit 1

EAS00492

INSTALLING THE CARBURETOR 1. Adjust: S engine idling speed Engine idling speed 1,450 X 1,650 r/min Refer to ADJUSTING THE ENGINE IDLING SPEED 2. Adjust: S throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY.

EAS00498

MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust. Fuel level (below the float chamber mating surface) 0 X 2.0 mm
a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c. Install the fuel level gauge 1 to the fuel drain pipe 2. Fuel level gauge 90890-01312 d. Loosen the fuel drain screw 3. e. Hold the fuel level gauge vertically next to the float chamber. f. Measure the fuel level a.
2. Adjust: S fuel level a. Remove the carburetor. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slightly bending the float tang 1. e. Install the carburetor. f. Measure the fuel level again. g. Repeat steps (a) to (f) until the fuel level is within specification.
FRONT WHEEL AND BRAKE DISC

EAS00512

CHASSIS

90 Nm (9.0 mSkg)

13 Nm (1.3 mSkg)
Job/Part Removing the front wheel and brake disc
Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Caps Speedometer cable Wheel axle Front wheel assembly Collar Meter gear unit assembly Brake disc

Refer to REMOVING/INSTALLING THE FRONT WHEEL section in chapter 6. (Manual No.: 5EK1-AE1)
REAR WHEEL AND REAR BRAKE

REAR WHEEL

Job/Part Removing the rear wheel
Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Adjuster Brake rod Pin Compression spring Chain case Axle nut/washer Chain pullers Wheel axle
Refer to REMOVING/INSTALLING THE REAR WHEEL section in chapter 6. (Manual No.: 5EK1-AE1)

Order 9

Job/Part Rear wheel assembly
Remarks Refer to REMOVING /INSTALLING THE REAR WHEEL section in chapter 6. (Manual No.: 5EK1-AE1) For installation, reverse the removal procedure.

Collar

REAR BRAKE AND REAR WHEEL SPROCKET

43 Nm (4.3 mSkg)

Job/Part Removing the rear brake and rear wheel sprocket Shoe plate Nuts Driven sprocket
Refer to ASSEMBLYNG THE REAR WHEEL section in chapter 6. (Manual No.: 5EK1-AE1) For installation, reverse the removal procedure.
Job/Part Disassembling the rear wheel Bearing Spacer Oil seal Bearing

FRONT FORK

23 Nm (2.3 mSkg)

30 Nm (3.0 mSkg)

Job/Part Removing the front fork Front wheel
Remarks Remove the parts in the order listed. Refer to FRONT WHEEL AND BRAKE DISC.
Brake hose holder Caliper Front fender Cap bolt/O-ring Bolt (upper bracket) Bolts (under bracket) Front fork assembly (left) Front fork assembly (right)
Refer to REMOVING/INSTALLING THE FRONT FORK section in cahpter 6. (Manual No.: 5EK1-AE1) NOTE: Loosen the bolt. For installation, reverse the removal procedure.

HANDLEBAR

20 Nm (2.0 mSkg)

Order 7

Job/Part Removing the handlebar Master cylinder bracket Master cylinder Housing (throttle grip) Throttle grip assembly Handlebar switch (right) Clutch switch Clutch cable
Refer to INSTALLING THE HANDLEBAR section in chapter 6. (Manual No.: 5EK1-AE1)

Order 8 9

Job/Part Handlebar switch (left) Grip (left)
Remarks Refer to REMOVING THE HANDLEBAR section in chapter 6. (Manual No.: 5EK1-AE1) Refer to INSTALLING THE HANDLEBAR section in chapter 6. (Manual No.: 5EK1-AE1) For installation, reverse the removal procedure.
Clutch lever Starter cable holder Upper holders Handlebar

STEERING HEAD

LOWER BRACKET
1st 38 Nm (3.8 mSkg) 2nd 18 Nm (1.8 mSkg)
Job/Part Removing the lower bracket Front fork Handlebar Headlight unit Headlight body Turn signal light assembly (left) Turn signal light assembly (right) Meter cable/Meter lead Meter assembly Headlight stay Steering stem nut Handlebar crown Lock washer Upper ring nut Rubber washer Lower ring nut

doc1

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the TW125 2003. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. TW125 SERVICE MANUAL: 5EK1-AE1 TW125 SUPPLEMENTARY SERVICE MANUAL : 5EK1-AE2
TWSUPPLEMENTARY SERVICE MANUAL E2002 by Yamaha Motor Co., Ltd. First Edition, October 2002 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EB001000

NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycle has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

CAUTION:

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to SYMBOLS on the following page. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (Periodic Inspections and Adjustments), where the sub-section title(-s) appear.
(In Chapter 3, Periodic Inspections and Adjustments, the sub-section title appears at the top of each page, instead of the section title.)
3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced (see SYMBOLS). 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially.

EAS00009

SYMBOLS
The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) 6 Chassis 7 Electrical system 8 Troubleshooting

GEN INFO

CHK ADJ

TRBL SHTG

Symbols 9 to 16 indicate the following. 9 Serviceable with engine mounted
Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data
Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points.
Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap base grease Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indicate the following:
23 Apply locking agent (LOCTITER) 24 Replace the part

CONTENTS

SPECIFICATIONS
GENERAL SPECIFICATIONS. 1 CHASSIS SPECIFICATIONS. 1 ELECTRICAL SPECIFICATIONS. 2 CABLE ROUTING. 3

ELECTRICAL

CHECKING THE SWITCHES. 13 LIGHTING SYSTEM. 14 CIRCUIT DIAGRAM. 14 TROUBLESHOOTING. 15

TROUBLESHOOTING

FAULTY LIGHTING SYSTEM. 17 HEADLIGHT DOES NOT COME ON. 17 HEADLIGHT BULB BURNT OUT. 17

TWWIRING DIAGRAM

GENERAL SPECIFICATIONS/CHASSIS SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Model code 5RS3, 5RS4 Standard SSS Limit

CHASSIS SPECIFICATIONS

Item Frame Frame type Caster angle Trail Tire pressure (cold tire) Maximum load-except motorcycle Loading condition A* front rear Loading condition B* front rear Off road riding front rear High speed riding front rear Diamond 25_mm 180 kg 0 X 90 kg 150 kPa (1.5 kg/cm2, 1.5 bar) 150 kPa (1.5 kg/cm2, 1.5 bar) 90 X 180 kg 150 kPa (1.5 kg/cm2, 1.5 bar) 175 kPa (1.75 kg/cm2, 1.75 bar) 125 kPa (1.25 kg/cm2, 1.25 bar) 125 kPa (1.25 kg/cm2, 1.25 bar) 150 kPa (1.5 kg/cm2, 1.5 bar) 175 kPa (1.75 kg/cm2, 1.75 bar) Standard SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Limit
*Load is the total weight of cargo, rider, passenger, and accessories.
CHASSIS SPECIFICATIONS/ ELECTRICAL SPECIFICATIONS
Item Front suspension Front fork travel Fork spring free length Fitting length Spring rate (K1) Stroke (K1) Oil capacity Oil level Oil grade Inner tube vend limit Rear suspension Shock absorber stroke Spring free length Fitting length Spring rate (K1) (K2) Stroke (K1) (K2) Drive chain Type/manufacturer No. of links Chain free play Rear brake Type Drum inside diameter Shoe thickness Shoe spring free length Standard 150 mm 330.4 mm 325.4 mm 4.9 N/mm (0.5 kg/mm) 0 X 150 mm 0.259 L (259 cm3) 122 mm Fork oil 10 WT or equivalent SSS 48 mm 190 mm 185 mm 127.5 N/mm (12.8 kg/mm) 186.4 N/mm (18.6 kg/mm) 0 X 32 mm 32 X 48 mm 428HD/DAIDO X 60 mm Leading, trailing 130 mm 4 mm 52 mm

Limit SSS 324 mm SSS SSS SSS SSS SSS SSS 0.2 mm SSS 173 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS 131 mm 2 mm SSS
ELECTRICAL SPECIFICATIONS
Item C.D.I. Pickup coil resistance/color Source coil resistance/color C.D.I. unit model/manufacturer Headlight relay Model/manufacturer Coil resistance Standard 656 X 984 at 20_C/ Red White 624 X 936 at 20_C/ Brown Green 5BT/YAMAHA G8MS-1A48T-L2-F28 /OMRON 90 X 110 SSS SSS SSS SSS SSS Limit

CABLE ROUTING

Brake hose Throttle cables Front brake light switch lead Right handlebar switch lead Main switch lead Clutch cable Clutch switch lead Speedometer cable Left handlebar switch lead Meter lead Front turn signal light lead (left)
12 Wire harness 13 Front turn signal light lead (right) 14 Indicator lead
A Clamp the grommet of brake hose with the band. After completion of clamping, cut the surplus part and point it to the backward. B No positioning for the headlight body is specified. C To the headlight D Clamp the left handle bar switch lead and the meter lead.
Battery positive lead Starter relay Starter motor lead Ignition coil Throttle cable (pull side) Throttle cable (return side) Throttle cable holder Horn lead Throttle cable guide Spark plug lead Headlight relay (Black) Relay (White)
13 C.D.I. unit 14 Diode 15 Turn signal relay
A Point the surplus part of the clamp of the wire harness to the downward. Clamp the immediate front part of the junction section to the C.D.I. unit relay. B Handlebar switch lead (right) and front brake light switch lead should not be twined around.
C Clamp the wire harness, handle- F Do not bend the lead sharply just bar switch lead (right), front after the terminal connection. brake light switch lead, clutch G Point the rear brake light switch switch lead, main switch lead, lead to the rear side of the veresonator hose and starter hicle. cable. H Route the lead by the front side D Clamp the ignition coil lead and of the sheet pillar tube so that it is the ignition coil grand lead horn not be caught between the side lead. cover flange and the frame sheet E Route the wire harness, handlepillar tube. bar switch lead (right) and front brake light switch lead through the guide.
I Secure the rear brake switch, knob-shape part of the lead, carburetor heater lead and turn signal relay lead. At this time, make sure to secure the turn signal relay lead at the outmost position. Next, point the surplus part of the band to the inner side and then cut it. J Relay lead can be routed either the front or the rear side of the relay.

K Push the wire harness in be- O Point the surplus part of the tween frame and box. clamp for the wire harness and L Place the C.D.I. unit on the atthe diode to the inner side. taching section of the left side Place the diode section between relay. the pipes of the frame. M Route the carburetor heater lead in the inner side of the turn signal relay. N Clamp the wire harness and diode. Point the surplus part to the downward.
Resonator hose Fuel hose Rectifier/ regulator lead Thermo switch lead Sidestand switch lead Air filter case Breather hose Battery negative lead C.D.I. magneto two leads Over flow hose Air vent hose Clutch cable Horn lead clamp
Clutch cable guide Brake hose Speedometer cable Horn Horn lead Flange bolt Brake hose holder Meter lead Handlebar switch lead (left)
A Clamp between the positioning belts of resonator hose. Do not pinch the resonator hose. B Starter cable, clutch switch lead and main switch lead should not be twined around. C Clamp at the point ahead of the part where resonator hose protector is torn. Do not pinch the resonator hose. D Place the coupler below the resonator hose.
E Clamp the rectifier / regulator G Clamp the C.D.I. magneto lead K Route the air vent hose and over lead and resonator hose. Point at the frame pipe bend and point flow hose between engine and the surplus part toward the inner the surplus part to the inner side, swingarm. side. Clamp within a range then cut it. L Route the neutral switch lead bewhere the resonator hose pro- H Clamp the sidestand switch tween engine and swingarm. tector is torn. Do not pinch the lead. M Pass the air vent hose and overresonator hose. I Clamp the air vent hose, over flow hose through the engine F Point the surplus part of the flow hosed and neutral switch guide. clamp to the rear side. Clamp the lead. N To the fuel cock. C.D.I. magnet leads (2 pieces), J Hold down the side stand switch O Insert the starter cable to the starter motor lead, neutral switch lead using the special washer. clamp. lead and battery negative lead.
P Clamp the brake hose and T Place the speedometer cable in speedometer cable. Align the the inner side. clamping position with the center U After tightening screws, insert of white paint mark on the brake the hose in the screw section. hose. V Distortion should be within this Q Clamp the brake hose and range toward the traveling direcspeedometer cable with a holdtion of vehicle. er. W Place the brake hose in the outer R Point the speedometer cable side. cap to the backward. X Cut the surplus part of the clamp S Make sure to push in the boot fulfor the left handle bar switch lead ly. and the meter lead.
Brake hose Throttle cable (return side) Throttle cable (pull side) Front brake light switch lead Handlebar switch lead (right) Starter motor lead Battery positive lead Wire harness Clamp (wire harness) Thermo switch lead Sidestand switch lead Grommet

Rectifier/ regulator Clamp (rectifier / regulator lead) Handlebar switch lead (left) Clutch switch lead Clutch cable Starter cable Neutral switch lead Connect cover C.D.I. magneto leads
A Clamp the handlebar switch lead and front brake light switch lead with a band. B Pass the C.D.I. magnet leads (3 pieces), neutral switch lead through the cover connector. C Clamp the wire harness and rear turn signal light lead (right). Point the surplus part to the inner side. D Cover the naked part of rear turn signal light lead (right) with the hose.
E Cover the naked part of rear turn signal light lead (left) with the hose. F Clamp the wire harness and rear turn signal lead (right). G Pass the rear turn signal light lead (right) between the rear frame and license bracket, avoiding to be caught. H Rout the lead by the outside of the frame so that it does not contact with the tip of the bolt as shown in the illustration.
I Pass the rear turn signal light M Route the battery negative lead lead (left) between the rear above the side stand switch lead frame and license bracket, and thermo switch lead. avoiding to be caught. N No special order is set for the J Clamp the rear turn signal light C.D.I. magneto lead (2 leads), lead (left). After clamping, point neutral switch lead, starter motor the surplus part to the inner side. lead and battery negative lead. K Clamp the thermo switch lead O Clamp the handlebar switch lead coupler. After clamping, point (left) and clutch switch lead. the surplus part to the inner side. P Route the thermo switch lead unL Battery negative lead to be conder the cover connector. nected with the ground. Q Route the starter motor lead under the cover connector.
R Route the sidestand switch lead under the cover connector. S Assemble so that the coupler and the lead are positioned lower than the batterys top face.

CHECKING THE SWITCHES

EAS00731
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to CHECKING SWITCH CONTINUITY in chapter 7 (Manual No.: 5EK1-AE1) Damage/wear Repair or replace the switch. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.

Turn signal switch Dimmer switch Horn switch Clutch switch Front brake switch
Engine stop switch Start switch Main switch Neutral switch Sidestand switch
11 Rear brake switch 12 Fuse 13 Thermo switch

LIGHTING SYSTEM

EB804000

CIRCUIT DIAGRAM

C.D.I magneto Rectifier/Regulator Battery Main fuse Main switch C.D.I unit Meter light Hi-beam indicator light Tail/Brake light Diode B Headlight relay Dimmer switch Headlight Auxiliary light

EAS00781

TROUBLESHOOTING Any of the following fail to light: head light, high beam indicator light, taillight, auxiliary light or meter light. Check: 1. fuse 2. battery 3. main switch 4. diode B 5. headlight relay 6. dimmer switch 7. wiring (of the entire charging system) NOTE: S Before troubleshooting, remove the following part(-s): 1) side covers (left and right) 2) seat 3) fuel tank S Troubleshoot with the following special tool(-s). Pocket tester 90890-03112

EAS00738

2. Battery S Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. (Manual No. : 5EK1-AE2) Minimum open-circuit voltage 12.8 V more at 20 _C S Is the battery OK? YES NO S Clean the battery terminals. S Recharge or replace the battery.

EAS00749

3. Main switch S Check the main switch for continuity. Refer to CHECKING THE SWITCHES in P13. S Is the main switch OK? YES NO Replace the main switch.
1. Fuse S Check the fuse for continuity. Refer to CHECKING THE FUSES in chapter 3. (Manual No. : 5EK1-AE1) S Is the fuse OK? YES NO Replace the fuse(-s).

EAS00760

4. Diode B S Disconnect the diode B from the wire harness. S Connect the pocket tester ( 1) to the diode B terminals as shown. S Measure the diode B for continuity as follows.
Tester positive probe ! brown/white 1 Tester negative probe ! white 2 Tester positive probe ! brown/white 1 Tester negative probe ! blue/black 3 Tester positive probe ! white 2 Tester negative probe ! brown/white 1 Tester positive probe ! blue/black 3 Tester negative probe ! brown/white 1

Battery positive terminal ! brown/white Battery negative terminal ! skyblue Continuity Tester positive probe ! brown 1 Tester negative probe ! blue/black 2
No continuity S Does the headlight relay have continuity between brown and blue/black? YES NO Replace the headlight relay. 6. Dimmer switch S Check the dimmer switch for continuity. Refer to CHECKING THE SWITCHES in P13. S Is the dimmer switch OK? YES NO The dimmer switch is faulty. Replace the left handlebar switch. 7. Wiring S Check the entire lighting systems wiring. Refer to CIRCUIT DIAGRAM. S Is the lighting systems wiring properly connected and without defects? YES Check the condition of each of the lighting systems circuits. Refer to CHECKING THE LIGHTING SYSTEM. (Manual No. : 5EK1-AE1) NO Properly connect or repair the lighting systems wiring.
NOTE: When you switch the testers positive and negative probes, the readings in the above chart will be reversed. S Are the testing readings correct? YES NO Replace the diode B.
5. Headlight relay S Disconnect the headlight relay from the wire harness. S Connect the pocket tester ( 1) and battery (12 V) to the headlight relay terminal as shown. S Check the headlight relay for continuity.

FAULTY LIGHTING SYSTEM

EAS00866
HEADLIGHT DOES NOT COME ON S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Improperly grounded circuit S Poor contacts (main or dimmer switch) S Headlight relay S Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT S Wrong headlight bulb S Faulty battery S Faulty rectifier/regulator S Improperly grounded circuit S Faulty main switch S Faulty dimmer switch S Faulty headlight relay S Headlight bulb life expired
C.D.I. magneto Neutral switch Rectifier/ Regulator Battery Main fuse Starter relay Starter motor Right handlebar switch Start switch Engine stop switch Main switch Diode A Clutch switch Sidestand switch Neutral relay C.D.I. unit Ignition coil Spark plug Speedometer Reed switch Meter light Neutral indicator light Turn signal indicator light Hi-beam indicator light Thermo switch Carburetor heater Rear brake light switch Front brake light switch Tail/ Brake light Diode B Headlight relay Turn signal relay Horn Left handlebar switch Horn switch Turn signal switch Dimmer switch Rear turn signal light (right) Front turn signal light (right) Front turn signal light (left) Rear turn signal light (left) Headlight Auxiliary light

 

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